U.S. patent application number 13/768590 was filed with the patent office on 2013-08-22 for light fixtures and processes for use thereof.
This patent application is currently assigned to LumenOptix, LLC. The applicant listed for this patent is LumenOptix, LLC. Invention is credited to Jay Goodman, Jaroslav Valerian, Yoram Weiss.
Application Number | 20130215623 13/768590 |
Document ID | / |
Family ID | 48982146 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130215623 |
Kind Code |
A1 |
Goodman; Jay ; et
al. |
August 22, 2013 |
Light Fixtures and Processes for Use Thereof
Abstract
A light housing is provided. Housing comprises plate with light
communication for LED luminaire attached to upper surface of plate,
annular base having a rim, plurality of supports connecting plate
to annular base, slots in each of plurality of supports; and
retention clips engaged within slots. Housing includes j-box
rotatably secured by support to plate with mounting brackets which
include locking detents to maintain support in upper or lower
positions. Also provided is fixture assembly comprising housing
with LED light attached thereto. Further methods for installing
assembly are provided and include positioning assembly through hole
in ceiling substantially within above-ceiling space, locking
retention clips against plurality of supports to maintain assembly
in position relative to ceiling; and engaging upper rim of
reflector with deflection clips attached to bottom surface of plate
of assembly.
Inventors: |
Goodman; Jay; (Blue Bell,
PA) ; Valerian; Jaroslav; (Harleysville, PA) ;
Weiss; Yoram; (Cherry Hill, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LumenOptix, LLC; |
|
|
US |
|
|
Assignee: |
LumenOptix, LLC
Montgomeryville
PA
|
Family ID: |
48982146 |
Appl. No.: |
13/768590 |
Filed: |
February 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61600391 |
Feb 17, 2012 |
|
|
|
61682974 |
Aug 14, 2012 |
|
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Current U.S.
Class: |
362/341 ;
362/362; 362/368; 362/370 |
Current CPC
Class: |
F21V 21/00 20130101;
F21V 17/164 20130101; F21V 29/77 20150115; F21V 21/042 20130101;
F21S 8/026 20130101; F21Y 2115/10 20160801 |
Class at
Publication: |
362/341 ;
362/368; 362/370; 362/362 |
International
Class: |
F21V 21/00 20060101
F21V021/00 |
Claims
1. A light fixture housing for an LED luminaire comprising: a plate
comprising a communication for light from the LED luminaire; an
annular base having a rim; a plurality of supports extending from
the plate to the annular base; and a slot aligned and positioned
through each of the plurality of supports.
2. The light fixture housing of claim 1 wherein at least one
mounting member for the LED luminaire is provided adjacent to the
communication.
3. The light fixture housing of claim 2 wherein the at least one
mounting member comprises a mounting surface positioned at about 90
degrees from a top surface of the plate.
4. The light fixture housing of claim 1 wherein the communication
comprises any geometric shape.
5. The light fixture housing of claim 1 wherein a first end of the
slot terminates adjacent to the annular base.
6. The light fixture housing of claim 5 wherein a second end of the
slot extends partially into the plate.
7. The light fixture housing of claim 5 comprising an opening in
communication with each slot wherein the opening is configured to
receive a retention clip.
8. The mounting fixture housing of claim 1 comprising a retention
clip, the retention clip comprising an bracket having an extended
arm and a fastener.
9. The mounting fixture housing of claim 8 wherein each bracket is
positioned along an outer surface of each support and wherein a
portion of the fastener communicates from an inner surface of each
support and through the slot.
10. The light fixture housing of claim 8 wherein the fastener is
threaded and adjustable.
11. The light fixture housing of claim 10 wherein the fastener
comprises a thumb screw, a wing nut, or bolt.
12. The light fixture housing of claim 8 wherein the fastener
comprises a latch comprising a lever arm, a tongue, and teeth, and
wherein the latch is in hinged communication with the bracket
having a support surface.
13. The light fixture housing of claim 12 wherein the latch can be
rotated relative to the bracket from an open position through
intermediate positions to a lock position.
14. The light fixture housing of claim 13 wherein the tongue of the
latch contacts the support surface the bracket when the latch is in
the intermediate positions and the lock position.
15. The light fixture housing of claim 1 comprising a plurality of
deflectable clips attached to a bottom surface of the plate.
16. The light fixture housing of claim 15 comprising a reflector
having a flange, wherein the flange of the reflector is secured by
the deflectable clips against the bottom surface of the plate.
17. The light fixture housing of claim 1 comprising mounting
brackets attached to a top surface of the plate wherein the
mounting brackets comprise support communications configured to
rotatably engage a support for an electrical box and locking
detents for the support.
18. The light fixture housing of claim 17 wherein the support
communications are configured to allow the support to rotate on a
axis that is parallel to the plate.
19. The light fixture of claim 17 wherein the locking detents
comprise an upper set of detents and a lower set of detents.
20. A light fixture assembly comprising: a plate comprising a
communication for light from a LED luminaire attached to an upper
surface of the plate; an annular base having a rim; a plurality of
supports extending from the plate to the annular base; a slot
aligned and positioned through each of the plurality of supports;
and a retention clip engaged within each slot.
21. The light fixture housing of claim 20 wherein a first end of
each slot terminates adjacent to the annular base.
22. The light fixture housing of claim 21 wherein a second end of
the slot extends partially into the plate.
23. The light fixture housing of claim 21 comprising an opening in
communication with each slot wherein the opening is configured to
receive a retention clip.
24. The mounting assembly of claim 20 wherein each retention clip
comprises a bracket having an extended arm and a fastener.
25. The light fixture housing of claim 24 wherein the fastener
comprises a threaded and adjustable fastener and an extended
arm.
26. The light fixture housing of claim 24 wherein the fastener
comprises a latch comprising a lever arm, a tongue, and teeth, and
wherein the latch is in hinged communication with the bracket
having a support surface.
27. The light fixture housing of claim 26 wherein the tongue of the
latch contacts the support surface the bracket when the latch is in
the intermediate positions and the lock position.
28. The light fixture housing of claim 20 comprising a plurality of
deflectable clips attached to a bottom surface of the plate.
29. The light fixture housing of claim 28 comprising a reflector
having a flange, wherein the flange of the reflector is secured by
the deflectable clips against the bottom surface of the plate.
30. The light fixture housing of claim 20 comprising mounting
brackets attached to a top surface of the plate wherein the
mounting brackets comprise support communications configured to
rotatably engage a support for an electrical box and locking
detents for the support.
31. The light fixture housing of claim 30 wherein the support
communications are configured to allow the support to rotate on an
axis that is parallel to the plate.
32. A method for installing a light fixture assembly comprising:
positioning the light fixture assembly through a hole in a ceiling
substantially within an above-ceiling space, wherein an annular
base of the light fixture assembly is level with or slightly above
a lower surface of the ceiling; positioning retention clips along
and partially within slots provided through a plurality of supports
of the light fixture assembly wherein extended arms of a bracket of
the retention clips contact an upper ceiling surface, locking the
retention clips in place against the plurality of supports to
maintain the position of the light fixture assembly relative to the
ceiling; and engaging an upper rim of a reflector with deflection
clips attached to a bottom surface of the plate of the light
fixture assembly.
33. The method of claim 32 wherein before positioning the light
fixture assembly through the hole in the ceiling, retention clips
are slid along the slots to an upper position adjacent the
plate.
34. The method of claim 32 wherein the step of positioning the
retention clips along slots comprises inserting a latch or the
bracket of the retention clip through an opening in communication
with each slot.
35. The method of claim 32 wherein the step of locking the
retention clip in place comprises tightening a threaded device to
secure the brackets of the retention clips against an outer surface
of each of support.
36. The method of claim 32 wherein the step of locking the
retention clip in place comprises rotating a lever arm of a latch
of the retention clip from an open position to a lock position.
37. The method of claim 36 wherein teeth of the lever arm engage an
inner surface of the support and a tongue of the latch places
downward force on a support surface of the bracket of the retention
clip while rotating the lever arm from the open position to the
lock position.
38. The method of claim 32 comprising before positioning the light
fixture assembly through a hole in a ceiling, rotating an
electrical box assembly into and secured in an upright position
relative to the light fixture assembly, wherein the electrical box
assembly comprises a support that rotatably engages communications
in mounts attached to a top surface of the plate of the light
fixture assembly.
39. The method of claim 32 wherein the electrical box assembly is
rotated to and secured in a lower position relative to the light
fixture assembly after the light fixture assembly is positioned
through the hole in the ceiling.
40. The method of claim 32 comprising connecting electrical service
to the light fixture assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority and benefit of U.S.
Provisional Patent Application Ser. No. 61/600,391, entitled "Light
Fixtures and Processes of Use Thereof," filed Feb. 17, 2012, and of
U.S. Provisional Patent Application Ser. No. 61/682,974, entitled
"Light Fixtures and Processes of Use Thereof," filed Aug. 14, 2012,
the entirety of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to apparatus and processes
for light fixtures and retrofit light fixtures and specifically to
LED downlight fixtures.
BACKGROUND OF THE INVENTION
[0003] LED lighting technology has become an alternative to
fluorescent, incandescent, and high-intensity discharge (HID)
lighting in commercial and residential settings. Similar to the
market entry of many new and emerging technologies, LED lights have
been expensive to buy and install, and, as a consequence, consumers
have relied on less costly alternative lighting, such as, for
example, incandescent, fluorescent, or HID lighting. Although the
upfront costs for LED lights are higher when compared to
alternative lighting, LED lights provide significant long-term
benefits. For example, LED lights use less energy than alternative
lighting. This results in lower electric bills. LED lights provide
illumination for a much longer time period than alternative
lighting. This longer life reduces the frequency of bulb
replacement and related costs. LED technology has evolved in recent
years to provide aesthetically-appealing illumination, and,
consequently, LED lighting has become a cost-effective, feasible
alternative to other sources of lighting.
[0004] The benefits of LED fixtures have drawn the attention of
commercial and residential consumers. This has led to an increase
in the selection and installation of LED lighting in new
construction, and, also, the replacement of traditional light
fixtures with LED fixture retrofits in existing building
infrastructure. New installation of LED fixtures is a
straightforward process because rough-in kits or remodeling ring
can be placed during construction. Retrofitting existing fixture
infrastructure can be challenging because the existing fixture must
be removed and the rough-in kit used and/or modified for new
fixture.
[0005] Thus, there is a need for LED fixtures that (1) can be used
for new and retrofit installations, (2) are cost effective to
install, (3) are simple to install, (4) can be installed without
the use of tools or a minimal amount of tools, (5) interface with
existing rough-in kits in retrofitting installations, (6) can be
installed with existing infrastructure (rough-in kits and holes in
the ceiling or tile) without the need to further cut into the
ceiling or tile, (7) can be installed from below the ceiling
through existing holes in the ceiling and rough-in kit or a
remodeling ring 400, (8) provide illumination that is
aesthetically-appealing to consumers, and (9) are environmentally
conscious because they do not implement lead and mercury typically
used in other types of light fixtures. The invention addresses
these needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Additional aspects, features, and advantages of the
invention, as to its structure, installation, operation, and use,
will be understood and become more readily apparent when the
invention is considered in light of the following description of
illustrative embodiments made in conjunction with the accompanying
drawings, wherein:
[0007] FIG. 1a shows an exploded, perspective view of the front of
a mounting assembly according to an illustrative embodiment of the
invention.
[0008] FIG. 1b shows an exploded, perspective view of the rear of
the mounting assembly shown in FIG. 1a.
[0009] FIG. 1c shows an exploded, perspective view of the left side
of the mounting assembly shown in FIG. 1a.
[0010] FIG. 1d shows an exploded, perspective view of the right
side of the mounting assembly shown in FIG. 1a.
[0011] FIG. 2a shows an elevation view of the left side of a
fixture assembly according to an illustrative embodiment of the
invention.
[0012] FIG. 2b shows an elevation view of the rear of the fixture
assembly shown in FIG. 2a.
[0013] FIG. 2c shows a perspective view of the top and rear of the
fixture assembly shown in FIG. 2a.
[0014] FIG. 2d shows a plan view of the bottom of the fixture
assembly shown in FIG. 2a.
[0015] FIG. 2e shows a plan view of the top of the fixture assembly
shown in FIG. 2a.
[0016] FIG. 2f shows a perspective view of the bottom and rear of
the fixture assembly shown in FIG. 2a.
[0017] FIG. 2g shows an elevation view of the right side of the
fixture assembly shown in FIG. 2a.
[0018] FIG. 2h shows an elevation view of the front of the fixture
assembly shown in FIG. 2a.
[0019] FIG. 3a shows an elevation view of the left side of a
fixture assembly having retention clips positioned adjacent the
bottom of the assembly according to an illustrative embodiment of
the invention.
[0020] FIG. 3b shows an elevation view of the rear side of a
fixture assembly having retention clips positioned adjacent the
bottom of the assembly
[0021] FIG. 3c shows an elevation view of the left side of a
fixture assembly having retention clips positioned adjacent the top
of the assembly shown in FIGS. 3a and 3b.
[0022] FIG. 3d shows elevation views of the rear side of a fixture
assembly having retention clips positioned adjacent the top of the
assembly shown in FIGS. 3a and 3b.
[0023] FIG. 4a shows an exploded, elevation view of the left side
of a fixture assembly according to an illustrative embodiment of
the invention.
[0024] FIG. 4b shows an exploded, elevation view of the rear of the
fixture assembly shown in FIG. 4a.
[0025] FIG. 4c shows an exploded, elevation view of the right side
of the fixture assembly shown in FIG. 4a.
[0026] FIG. 4d shows an exploded, perspective view of the front and
left side of the fixture assembly shown in FIG. 4a.
[0027] FIG. 4e shows an exploded, perspective view of the front and
right side of the fixture assembly shown in FIG. 4a.
[0028] FIG. 4f shows a perspective view of another embodiment of
the fixture assembly shown in FIG. 4a.
[0029] FIG. 4g shows an elevation view of the left side of the
fixture assembly shown in FIG. 4f.
[0030] FIG. 4h shows a perspective view of the front and right side
of the fixture assembly shown in FIG. 4f with the light engine and
heat sink removed.
[0031] FIG. 5 shows a perspective view of the top and rear of a
fixture assembly according to a further embodiment of the
invention.
[0032] FIG. 6 shows a partially-exploded, perspective view of the
top and left side of the fixture assembly shown in FIG. 5.
[0033] FIG. 7 shows a plan view of the top of the fixture assembly
shown in FIG. 5.
[0034] FIG. 8 shows a perspective view of the bottom and rear of
the fixture assembly shown in FIG. 5.
[0035] FIG. 9 shows a partially-exploded, perspective view of the
bottom and right side of the fixture assembly shown in FIG. 5.
[0036] FIG. 10 shows a perspective view of the left side of the
fixture assembly shown in FIG. 5.
[0037] FIG. 11 shows a sectional view of the fixture assembly shown
in FIG. 5.
[0038] FIG. 12 shows a perspective view of the top and front of the
housing shown in FIG. 5.
[0039] FIG. 13 shows a perspective view of the bottom and rear of
the housing shown in FIG. 12.
[0040] FIG. 14 shows a perspective view of the top and left side of
a fixture assembly according to an even further embodiment of the
invention.
[0041] FIG. 15 shows a plan view of the top of the fixture assembly
shown in FIG. 14.
[0042] FIG. 16 shows a partially-exploded, perspective view of the
top and left side of the fixture assembly shown in FIG. 14.
[0043] FIG. 17 shows a perspective view of the bottom and rear of
the fixture assembly shown in FIG. 14.
[0044] FIG. 18 shows a partially-exploded, perspective view of the
bottom and right side of the fixture assembly shown in FIG. 14.
[0045] FIG. 19 shows a perspective view of the left side of the
fixture assembly shown in FIG. 14.
[0046] FIG. 20 shows a sectional view of the fixture assembly of
FIG. 14.
[0047] FIG. 21 shows a perspective view of a torsion spring
according to an embodiment of the invention.
[0048] FIG. 22 shows a perspective view of a mounting bracket
according to an embodiment of the invention.
[0049] FIG. 23 shows a perspective view of a wire form assembly
according to an embodiment of the invention.
[0050] FIGS. 24a, 24b, and 24c show perspective views of the left
side of a bracket assembly according to an embodiment of the
invention.
[0051] FIGS. 25a, 25b, and 25c show elevation views of the left
side of the bracket assembly shown in FIGS. 24a, 24b, and 24c.
[0052] FIGS. 26a, 26b, and 26c show perspective views of the bottom
and left sides of the bracket assembly shown in FIGS. 24a, 24b, and
24c.
[0053] FIGS. 27a, 27b, and 27c show perspective views of the rear
and left sides of the bracket assembly shown in FIGS. 24a, 24b, and
24c.
[0054] FIG. 28a shows a plan view of the top of a remodel ring
according to an embodiment of the invention.
[0055] FIG. 28b shows a perspective view of the front of remodel
ring shown in FIG. 28a with portions of the remodel ring deflected
along a cut.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0056] Illustrative and alternative embodiments of apparatus and
processes for light fixtures and retrofit light fixtures and
specifically to LED downlight fixtures are described in reference
to the figures of the application. While illustrative embodiments
of the invention are shown and described as fixture assembly 10 or
1010, alternative embodiments of the invention as well as its
features, components, and functionality are described in this
application.
[0057] Embodiments of the invention can be used in new construction
and as retrofits or replacements for installed lighting assemblies.
Accordingly, the invention provides processes for installing
fixture assemblies 10 and 1010 in new construction, such as, high
bay, low bay, ceiling space, and the like, and, also, in
retrofitting existing light fixtures, such as, fluorescent,
incandescent, or HID lighting in high bay, low bay, ceiling space,
and the like. In new construction, a rough-in kit (e.g., plate,
j-box, ballast, and electric supply) or alternatively remodeling
ring 1400 must be positioned above the ceiling or ceiling tile and
a hole must be cut through the ceiling or ceiling tile to
correspond with a hole in the plate of the rough-in kit or in
remodeling ring 1400. In retrofit applications, the reflector of an
existing, installed fixture must be removed and the rough-in kit
(plate, j-box, ballast, and electric supply) can be left in place
above the ceiling and used with the installation of fixture
assembly 10 or 1010. Alternatively, the rough-in kit can be
displaced or removed and a remodeling ring 1400 used in its
place.
[0058] Illustrative embodiments of fixture assembly 10 are shown in
FIGS. 2a-4e. Assembly 10 comprises mounting assembly 200, LED
driver 300, LED light 400, and reflector 500.
[0059] Referring now to FIGS. 1a-4h, mounting assembly 200
comprises plate 205 attached to a plurality of support arms 210
contiguous with ring 215 having flange 216. In an embodiment shown
in FIGS. 1a-1d, plate 205 has communication 225. Communication 225
has a square shape defined by edges of plate 205 as shown in FIGS.
1a-1d. While illustrated as a square, the geometric shape of
communication 225 may comprise any suitable geometric shape, e.g.,
round, oval, triangular, rectangular, etc. The geometric shape can
be configured to correspond with the shape of LED light 400
intended for use with fixture assembly 10. Communication 225
permits emission of illumination from LED light 400 secured to
mounting plates 230.
[0060] Two mounting plates 230 projecting at about 90 degrees from
the surface of plate 205 positioned adjacent to communication 225.
Mounting plates 230 are provided to secure LED light 400
accompanied with LED driver 300 to mounting assembly 200 as shown,
for example, in FIGS. 2a-4e. Furthermore, a plurality of deflection
clips 235 can be attached to plate 205 also shown in FIGS. 2a-4e.
Deflection clips 235 have indentations which engage upper rim 501
of the assembly's reflector 500.
[0061] In an alternative embodiment, torsion springs 1300 (which
are described greater detail relative to fixture assembly 1010) may
be used in place of deflection clips 235. Torsion springs 1300
provide a functionality that is similar to deflection clips 235.
Plate 205 can be configured with communications (similar to that of
top platform 1020) to secure torsion springs in place to plate
205.
[0062] In embodiments shown specifically in FIGS. 1a-1d, multiple
rivets are used to secure plate 205 to plurality of support arms
210. In alternative embodiments, other attachment devices can be
used to secure plate 205 to support arms 210, e.g., screws, weld
joints, or the like. The plurality of support arms 210 shown in
FIGS. 1a-4h consist of three support arms. Any number of support
arms 210 may be used without limitation in connection with mounting
assembly 200. Each support arm 210 includes slotted communication
255 (also referred to as slot) to guide and control movement of
retention clip 260 as shown in FIGS. 1a-4h, or, alternatively,
bracket assembly 1400 as shown for example in FIG. 16. Slot 255
extends from aspects of plate 205 along the length of each support
arm 210 to ring 215. Communication 255 may extend into plate 205
and also into ring 215. Communication 255 permits positioning of
clip 260 from an upper position adjacent plate 205, as shown in
FIGS. 2c-2d, to lower positions in support arm 210 shown in FIGS.
3a-3b.
[0063] Each retention clip 260 can be secured to its corresponding
support arm 210 with fastener 299 that can be partially positioned
within slot 255. Fastener 299 is configured to provide a friction
fit to secure retention clip 260 to support arm 210. fastener 299
can also be loosened so that it can slide along slot 255 and move
the retention clip 260 relative to support arm 210. Fastener 299
can comprise any mechanism that can manipulate (tighten or loosen)
a bolt within a corresponding threaded communication of retention
clip 260, or that can engage a bolt or the like attached to
retention clip 260. For example, fastener 299 can be a thumbscrew
(as shown, for example, in FIGS. 1a-1d), wing nut, or the like.
Alternatively, bracket assembly 1400 can be secured to a
corresponding support arm 210 as described in greater detail in
relation to fixture assembly 1010. Bracket assembly 1400 locks into
place and forms a friction fit to secure bracket assembly 1400 to
support arm 210.
[0064] Referring now to FIGS. 1a-4h, ring 215 is provided along the
lower aspect of mounting assembly 200. As shown, for example, in
illustrative embodiments in FIGS. 1a-1d, ring 215 can be contiguous
with support arms 210, but can also be attached as a part to
support arms 210 similar to the manner in which plate 205 is
attached to the upper portions of support arms 210. Ring 215
includes flange 216 that protrudes away from ring 215 at about 90
degrees as shown specifically in FIGS. 1a-1d. In an alternative
embodiment, flange 216 includes lower portions of support arms 210
that bend at about 90 degrees from the surface of flange 216 and
are connected to upper portions of support arms that extend away
from plate 205.
[0065] Referring now to FIGS. 4f-4h, member 1250 is rotatably
attached by clip 1252 to plate 205 of mounting assembly 200. Member
1250 permits J-box 1100 to rotate from a vertical position as shown
in FIGS. 4f-4h to a horizontal or other non-vertical position (not
shown). Member 1250 may include extension tabs that can be
positioned in locking slots in plate 205 to assist in maintaining
member 1250 in the vertical position. Member 1250 permits the
elevation of J-box 1100 into a position above fixture assembly 10
to facilitate ease in installation as described in further detail
in this application. The length of member 1250 can vary to provide
clearance for any size of heat sink when member 1250 is positioned
in a substantially vertical configuration as shown in FIGS. 4f-4h.
Member 1250 may be used with either fixture assembly 10 or
1010.
[0066] The invention also provides processes for installing fixture
assembly 10 in new construction and retrofits. Remodeling ring 4000
can be installed by deflecting first edge 4020 from second edge
4040 along cut 4010 as shown in FIGS. 28a and 28b. With an existing
or new rough-in kit, or alternatively, remodeling ring 4000 in
place above a ceiling, fixture assembly 10 is prepared for
installation. Fastener 299, such as a thumb screw, is loosened so
that retention clips 260 can be moved to the upper position shown
in FIGS. 3c-3d. Alternatively, and if bracket assembly 1400 is
used, then bracket assembly 1400 is either removed or moved to an
upper position to allow insertion of fixture assembly 10 or 1010
through the hole in the ceiling. Member 1250 can be rotated to a
vertical position (as shown in FIGS. 4f-4h) if member 1250 is not
already in this vertical position. From below the ceiling, the LED
light/LED driver is connected to a new power supply, which can also
be referred to as a driver, ballast, control gear, or the like. The
power supply is also connected to the existing electrical wires
that provide electric service to the LED light. Optionally, a
tether such as a wire cable can be connected to both the rough-in
kit and fixture assembly 10 or 1010 to assist in holding assembly
10 or 1010 while electrical connections are made.
[0067] Fixture assembly 10 is then inserted, J-box 1100 first,
through the hole in the ceiling and corresponding hole of the
rough-in plate or remodeling ring 4000. Flange 216 of fixture
assembly 10 is positioned as close as possible to the hole of the
rough-in plate or remodeling ring 4000. In an embodiment, flange
216 may rest against the hole of the rough-in plate or, if present,
a cylindrical projection (of the rough-in plate) that defines, in
part, the hole of the rough-in plate. In another embodiment, flange
216 may be positioned within the hole in the ceiling, but not in
contact with the rough-in plate. In a further embodiment, flange
216 may be positioned flush with the exposed surface of the
ceiling.
[0068] With fixture assembly 10 in place, retention clips 260 or
bracket assemblies 1400 are slid along slot 255 to a lower position
(e.g., shown in FIGS. 3a-3b) to contact the upper surface of the
rough-in plate or remodeling ring 4000. If using retention clips
260, then fasteners 299 for retention clips 260 are tightened. This
secures each clip 260 in place on support arms 210, and,
consequently, fixture assembly 10 in place adjacent the rough-in
kit or remodeling ring 400 and the ceiling. Alternatively, and if
using bracket assemblies 1400, then lever arm 1404 is snapped
closed into a locked position on supports arms 210.
[0069] Reflector 500 is inserted through ring 215. Reflector 500 is
pressed upwards so that its upper rim 501 engages indentations of
deflection clips 235 shown, for example, in FIGS. 3a-3b or torsion
springs 1300. Deflection clips 235 or torsion springs 1300 secure
reflector 500 to fixture assembly 10. When reflector 500 is secured
in place with an installed fixture assembly, the reflector's lower
rim 502 may contact the surface of the ceiling or tiles or bottom
surface of flange 216. It is recognized that this installation
process can be modified for various conditions of new construction
and retrofitting existing structures.
[0070] Another illustrative embodiment of the invention is fixture
assembly 1010 depicted throughout FIGS. 5-27c. This assembly 1010
comprises housing 1012. In one embodiment, housing 1012 is shown in
FIGS. 5-20 as a monobody having top platform 1020 connected by
vertical supports 1014 to ring 1024 having flange 1026. In
alternative embodiments, housing 1012 may be formed from one or
more parts attached together by fittings such as, for example,
rivets. Housing 1012 is the main infrastructure of fixture assembly
1010.
[0071] Referring now to FIGS. 12 and 13, several communications are
provided with housing 1012 for different purposes. Light
communication 1022 is provided in top platform 1020 to permit the
passage of light from an LED light positioned adjacent top platform
1020. While illustrated as a square, the geometric shape of light
communication 1022 may comprise any suitable geometric shape, e.g.,
round, oval, triangular, rectangular, etc.
[0072] Openings 1018 are also provided near the top of each
vertical support 1014 as shown, for example, in FIGS. 8-10, 12-13,
and 16-18. Openings 1018 provide passage for bracket assembly 1400
to be installed in slots 1016 of housing 1012. For example, and
with bracket assembly 1400 in a released position, latch 1402 can
be passed through opening 1018 from the outside of housing 1012.
Alternatively, bracket 1408 can be passed through opening 1018 from
the inside of housing 1013. In either instance, bracket 1408 rests
on the outside surface of vertical support 1014 and latch 1402
rests on inner surface of vertical support 1014. Latch's tongue
1405 and portions of bracket's support surface 1411 communicate
through slot 1016.
[0073] Slot 1016 is provided vertically and centrally along each
vertical support 1014 shown specifically in FIGS. 12 and 13. Slot
1016 extends from opening 1018 running along vertical support 1014
and terminates above ring 1024. Slot 1016 guides bracket assembly
1400, which when in a released position, slides along vertical
support 1014. Alternatively, retention clips 260 can be used as
described in relation to fixture assembly 10.
[0074] Referring to FIGS. 24a-c, 25a-c, 26a-c, and 27a-c, bracket
assembly 1400 comprises latch 1402 hinged together with bracket
1408. Latch 1402 comprises tongue 1405 and lever arm 1404. Tongue
1405 is configured to contact and interact with support surface
1411 of bracket 1408 while locking bracket assembly 1400 in place
on vertical support 1014. The purpose of lever arm 1404 is to
removeably secure bracket 1408 to vertical support 1014. Bracket
assembly 1400 is configured for use within slot 1016 as shown, for
example, in FIGS. 6 and 14, and is used to install fixture assembly
1010 as described in detail in this application. Bracket assembly
1400 (e.g., preinstalled or installed after inserting fixture
assembly 10 or 1010 through hole in ceiling) can also be used with
slot 255 as shown in FIGS. 2a through 4h.
[0075] Operation of bracket assembly 1400 can occur without tools
and without fasteners. For example, lever arm 1404 is shown in a
released position in FIGS. 24a, 25a, 26a, and 27a. Lever arm 1404
can be pressed upward relative to bracket 1408. As lever arm 1404
is rotated upward, teeth 1406 of lever arm 1404 contact with and
removeably imbed within an inner surface of vertical support 1014.
Embedded teeth 1406 function as a leverage point for locking and
unlocking bracket assembly 1400. Latch 1402 interconnects with
bracket 1408 so that latch 1402 can partially rotate (about 180
degrees) along an axis that is generally perpendicular to the
vertical alignment of bracket 1408.
[0076] Referring now to FIGS. 24b, 24c, 25b, 25c, 26b, 26c, 27b,
and 27c, moving lever arm 1404 upward causes tongue 1405 to push
downward on support surface 1411 of bracket 1408. Consequently, and
with teeth 1406 imbedded into inner surface of vertical support
1014, tongue 1405 pushes bracket 1408 in a downward direction. As
lever arm 1404 is moved further upward as shown in FIGS. 24c, 25c,
26c, and 27c, tongue 1405 pushes bracket 1408 further down to
relative to support arm 1014. Tongue 1405 eventually passes a
geometric high point and snaps lever arm 1404 into a locked
position against vertical support 1014 as shown in FIGS. 9 and 18.
In this locked position, vertical support 1014 is sandwiched
between bracket 1408 and lever arm 1404 thereby creating a friction
fit.
[0077] Referring to FIG. 23, wire form 1202 is provided to attach
J-box 1100 to mounting brackets 1600 of housing 1012. Wire form
1202 comprises a u-shaped support 1204 with arms 1208 having ends
1206. J-box 1100 has cover 1102 that is secured without fasteners
and without tools. Referring to FIGS. 5-8 and 14-17, ends 1206 of
arms 1208 rotatably engage corresponding communications in mounting
brackets 1600 that are attached along the top of top platform 1020
of housing 1012. Mounting brackets 1600 are provided in various
embodiments including one embodiment that generally extends
substantially along the length of top platform 1020 as shown in
FIGS. 5-7 and 14-16 and another that is positioned adjacent light
engine attached directly to top platform 1020. Wire form 1202 and
mounting brackets 1600 can also be used with fixtures assembly
10.
[0078] Wire form 1202 is secured to and can be removed from
mounting bracket 1600 without fasteners and without tools. A
portion of arms 1208 adjacent ends 1206 removeably engage detents
provided with mounting brackets 1600 as shown in FIGS. 5-6 and
14-15. The detents secure wire form 1202 and consequently J-box
1100 in several positions relative to housing 1012. For example,
sets of corresponding detents are provided as upper detents 1602,
middle detents 1604, and lower detents 1606 as shown in FIGS. 6,
16, and 22. Arms 1208 are substantially rigid to support J-box 1100
in a horizontal or non-vertical position in middle and lower
detents 1604 and 1606. Arms 1208 can be moved from one set of
detents to another by pushing the J-box 1100 up or down and
allowing the arms 1208 to snap into place in a set of corresponding
detents. Arms 1208 are deflectable if squeezed together by hand to
release engagement of arms 1206 from detents and to rotate wire
form 1202 and J-box 1100 into position in another set of detents or
to remove wire form 1202 from mounting brackets 1600. The length of
arms 1208 can vary to provide clearance for heat sinks when wire
form 1202 is positioned in upper detents 1602.
[0079] Referring generally to FIGS. 6, 9, and 17-18, reflector 1500
comprises top flange 1502, body 1503, and bottom flange 1504. Top
flange 1502 of reflector 1500 is configured to removeably engage
torsion springs 1300 that secure reflector 1500 to top platform
1020. Torsion springs 1300 are attached by ends 1306 that engage
communications provided through top platform 1020, as shown in
FIGS. 5, 6, 9, 11, 18, and 20, without fasteners and without tools.
Torsion spring 1300 includes coil 1302 that permits deflection of
securement 1304 away from its bias toward the vertical axis of
fixture assembly 1010 when torsion spring 1300 is installed with
housing 1012. Alternatively, deflection clips 235 can also be used
with housing 1012.
[0080] Referring generally to FIG. 6, light engine 1800 can be
secured to mounting brackets 1600 or, alternatively, directly to
top platform 1020 of housing 1012. Light engine 1800 is positioned
relative to housing 1012 so that light can be emitted through
communication 1022.
[0081] Fixture assemblies 10 and 1010 function as heat radiators
and, in combination with heat sink 1700, assist in heat dissipation
for the LED engine. For example, and in embodiments where mounting
assembly 200 of fixture assembly 10 and housing 1012 of fixture
assembly 1010 are manufactured from metal or metal alloy such as
aluminum, assembly 200 and housing 1012 assist heat sink 1700 with
heat management of the LED light or light engine 1800. Indeed, the
heat generated by the LED light or light engine 1800 is conducted
through the mounting brackets to the mounting assembly and housing.
In an alternative embodiment with the LED light or light engine
attached directly to top plate 205 or top platform 1020, heat can
also be conducted to and dissipated by the mounting assembly and
housing. The length of heat sinks 1700 can also be varied to
optimize heat dissipation for various LED power packages. Heat
management assists with optimizing the function and life of the LED
light or light engine.
[0082] The installation methods for the second embodiment of
fixture assembly 1010 can be performed without tools. Similar to
fixture assembly 10, fixture assembly 1010 can be installed in new
construction and also in retrofit installations. If installing in
new construction, a rough-in kit or remodeling ring 4000 may be
positioned above the ceiling and a hole must be cut into the
ceiling that corresponds with a hole in the plate of a rough-in kit
or remodeling ring 4000. For retrofits, the reflector of the
installed fixture must be removed and the rough-in kit must remain
in place above the ceiling or pushed to the side and a remodeling
ring 400 may optionally be used rather than rough-in kit.
[0083] A tether can be used to assist in installation of assembly
1010 similar to installation of assembly 10.
[0084] Fixture assembly 1010 is prepared for installation. The
first step of installing comprises attaching electric services to
LED driver 1900 in J-box 1100 while fixture assembly 1010 is below
the ceiling. Arms 1208 of wire form 1202 are placed in upper
detents 1602 of mounting bracket 1600. Of course, this can occur
before or after electric service is attached to LED driver 1900. If
arms 1208 are not already engaged in upper detents 1602, arms 1208
can be squeezed together by hand to clear detents 1604 or 1606 but
without removing ends 1206 from the communications of mounting
bracket 1600. With arms 1208 clearing detents 1604 or 1606, wire
form 1202 is rotated upwards and pressure released to allow arms
1208 to engage upper detents 1602. In this configuration, wire form
1202 and J-Box 1100 are generally positioned above housing 1012,
light engine 1800, and heat sink 1700.
[0085] The next step of installation is to insert housing 1012 with
wire form 1202 in upper detents 1602 through the hole cut in the
ceiling. Alternatively, wire form 1202 may engage detents 1604 or
1606. Flange 1026 of housing ring 1024 may be placed flush with the
bottom (exposed part) of the ceiling. In an alternative embodiment,
flange 1026 may be placed within or even above the hole of the
ceiling.
[0086] Retention clip 260 may be used with housing 1012 to install
fixture assembly 1010 in a similar manner as fixture assembly
10.
[0087] Bracket assemblies 1400 may be preinstalled with housing
1012 and vertically adjusted so that legs 1409 of bracket 1408
contact either the rough-in plate, remodeling ring 4000, or the top
surface of the ceiling. Prior to inserting fixture assembly 1010
through the hole in the ceiling, bracket assemblies 1400 are
positioned in an upper position along slots 1016 of vertical
supports 1014. In an alternative embodiment, and with bracket
assemblies 1400 removed from housing 1012, fixture assembly 1010 is
inserted through the hole in the ceiling. Then, bracket assemblies
1400 are installed by sliding brackets 1408 through openings 1018
from the inside of housing 1012. Lever arm 1404 should be in the
released position or close to it. Each bracket assembly 1400 is
then slid down along slots 1016 to rest on top surface of plate of
rough-in kit, remodeling ring 400, or ceiling.
[0088] Each bracket assembly 1400 is then used to secure fixture
assembly 1010 in place to a structure, such as, for example, the
top of a ceiling or ceiling tile. Lever arm 1404 is pushed upward
toward top platform 1020 to lock bracket assembly 1400 in position
and to secure fixture assembly 1010 in place. As lever arm 1404 is
pushed upward, teeth 1406 of lever arm 1404 embed in the inner
surface of vertical support 1014. This pivotally secures lever arm
1404 to vertical support 1014 to assist in locking bracket assembly
1400. As lever arm 1404 continues to be pushed upward into the
locked position, tongue 1405 of lever arm contacts support surface
1411 of bracket and pushes bracket 1408 in an opposite direction
from the direction of movement of lever arm 1404. In other words,
bracket 1408 is pushed down relative to vertical support 1014 while
lever arm 1404 pivots upward into the locked position. Deflected
prongs 1416 are provided with bracket 1408 to stabilize bracket
1408 against the semi-circular profile of vertical support
1014.
[0089] Support surface 1411 of bracket 1408 is spring-like and
pushes against tongue 1405 of lever arm 1404 creating an even
tension. As tongue 1405 of lever arm 1404 slides along support
surface 1411, bracket 1408 continues to be pushed downward to
tighten the housing against the ceiling (if the flange of the ring
is not positioned within the hole in the ceiling). Once the lever's
tongue 1405 moves past a geometric high point on support surface
1411, lever arm 1404 snaps into the locked position against
vertical support 1014, creating a friction fit with vertical
support 1014. Lever arm 1404 lays flat against inner surface of
vertical support 1014 of housing 1012, allowing for installation of
reflector 1500. This function is particularly beneficial when using
wide-distribution reflectors that leave limited space between the
reflector and the housing.
[0090] This step of locking bracket assembly 1400 is repeated for
each bracket assembly 1400. The installation and locking of bracket
assembly 1400 can be achieved by hand without the use of tools.
[0091] Lever arm 1404 can easily be moved from the secured position
to the released position by moving lever arm 1404 away from top
platform 1020 and toward ring 1024. As lever arm 1404 is moved, the
friction fit is released, teeth 1406 disengage vertical support
1014, and tongue 1405 of lever arm 1404 is removed from contact
with support surface 1411 of bracket 1408.
[0092] Wire form 1202 can be moved to middle or lower detents 1604
or 1606 at any time before installation of reflector 1500.
[0093] Reflector 1500 is then positioned substantially through the
hole in the ceiling. With top flange 1502 of reflector 1500 in
contact with deflection portions 1304 of torsion springs 1300,
reflector 1500 is pushed toward top platform 1020 to offset
deflection portion 1304 of torsion springs 1300 until deflection
portion 1304 returns to its biased position to secure top flange
1502 of reflector 1500 in place adjacent top platform 1020 of
housing 1012. Deflection clips 235 can also be used in place of
torsion springs 1300.
[0094] Assemblies 10 and 1010 can be configured as, or to replace,
any size fixture including, but not limited to, standard sizes for
commercial and residential fixtures and custom sizes. For example,
standard sizes include ring 215 or ring 1024 with 4-inch diameter,
6-inch diameter, 8-inch diameter, or any other standard size.
Furthermore, the height of support arms 210 or vertical supports
1014 may also vary depending upon the diameter of ring 215 or ring
1024, geometric shape and/or size of the reflector, strength of
illumination of LED light 400 or 1800, installation space above a
ceiling or cabinet, or any other parameter that would affect the
size of fixture assembly 10 or 1010. Fixture assembly 10 or 1010
can be customized to fit or retrofit any installation space.
[0095] Assemblies 10 and 1010 including all of their components can
be fabricated with any one or combination of the following
materials: metal or metal alloy, plastic, composite material, or
the like.
[0096] Any make, model, size, and lumen LED light, LED engine, and
LED driver, and heat sink, can be used with fixture assemblies 10
and 1010 and can be sourced from any manufacturer or vendor. By way
of non-limiting example, the Philips Fortimo light engine, GE
Infusion LED light engine, or the like can be used with the
invention. Also, high lumen LED modules may also be used with the
invention.
[0097] While the invention is described in conjunction with
specific embodiments, it is evident that many alternatives,
modifications, permutations, and variations will become apparent to
those skilled in the art in light of the foregoing description.
Accordingly, it is intended that the invention embraces all such
alternatives, modifications, permutations, and variations as
falling within the scope of the claims below.
* * * * *